HYDRAULIC AND PARK BRAKE SYSTEMS
Brake Cluster Assembly Inspection and Cleaning
Page 6-10 2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual
6
BRAKE CLUSTER ASSEMBLY INSPECTION AND CLEANING
Read WARNING on page 6-1.
∆ WARNING
• If at any point in this procedure the hydraulic system is opened, the brakes must be bled after
the correct reinstallation of the brake components. Failure to bleed the brakes could result in
decreased braking performance due to air being trapped in the hydraulic system. Use only
DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-29.
NOTE: Factory installed brake shoes on the Pioneer 1200 have non-asbestos linings. When replacing brake
shoes, Club Car recommends non-asbestos replacement parts.
1. Remove the brake drum and brake shoes. See Brake Drum Removal on page 6-7 and Brake Shoe
2. Clean the brake cluster backing plate and all of the brake cluster components.
3. Check the brake shoe adjusters in each brake cluster assembly for proper operation.
3.1. With the brake drum removed, gently rotate the adjusters with a torque wrench and hydraulic
brake adjuster (CCI 102169401). If the adjusters require more than 65 in-lb (7.3 N·m) of force to
rotate, they must be replaced.
4. Check the wheel cylinder for signs of leakage. If there are signs of leakage, replace the wheel cylinder.
See Wheel Cylinder Replacement on page 6-19.
5. Check all springs for loss of tension and damage. Replace weak springs and any damaged or badly
worn parts.
6. For the rear brake clusters, ensure that the park brake lever and strut assembly (14) can be easily
moved by hand (Figure 6-18, Page 6-20). If the assembly can be easily moved by hand, proceed to step
7. If the assembly cannot be easily removed by hand, cleaning and lubrication will be necessary.
6.1. Remove the park brake cable pin (2) and clevis (3) from the lever and strut (Figure 6-15, Page 6-18).
6.2. Remove the lever and strut (14) from the brake cluster assembly (Figure 6-18, Page 6-20).
Figure 6-5 Rotate Cup and Spring Assembly
Figure 6-6 Remove Brake Shoes
